Chewing tobacco product



Jan. 19, 1965 H. P-Zlv-LE ETAL CHEWING TOBACCO PRODUCT Filed April 5". 1961 lllll w SA 5 Z R T rv... new n N Naam m EMSL l l WR SL T I AJEW A D.. LB .K 1 BmwH r EEY M A m HFCJ Y B United States Patent O 3,166,078 CHEWING TOBACCU PBGDUCT Harris B. Pannele, Glen Ridge, NJ., and Frederick J.

Schultz, Chase W. Lassiter, @d irnrny H. Bell, Greensboro, N.C., assignors to P. Lorillard Company, New York, NX., a corporation of New Jersey Filed Apr. 5, 1961, Ser. No. 100,842 2 Ciaims. (Cl. 131-5) This invention relates to tobacco products and to methods and apparatus for making the same, and has particular reference to restoring waste tobacco into usable form especially adapted for mixture with, or as, chewing tobacco.

It is well known that during the stripping of leaf tobacco in prepartion for its use for cigar wrappers or filler, cigarettes and smoking tobacco, a substantial quantity of stems and leaf scraps remains as waste although some of its has been used for making snuff and for mixture with chewing and smoking tobacco. In addition there is the tobacco scrap and dust resulting from shipping, handling and other causes. Inasmuch as this so-called Waste is high grade, flavorful tobacco, numerous proposals for vits economic use have been made, principally its conversion into the form of synthetic leaf or reconstitute tobacco made by adhesively binding finely ground tobacco and forming the mixture into sheets, ribbons or the like and substituting the same in whole or in part for natural leaf in cigars, cigarettes, smoking tobacco and other tobacco products.

In addition to the problem of impairment of the tobacco flavor in the smoke from burning reconstituted tobacco caused by the adhesive binders used for uniting the fine tobacco particles into a reconstituted sheet, there are economic and other disadvantages resulting from this practice. For example, the commercial use of wellknown paper making techniques in manufacturing such reconstituted tobacco in sheet or ribbon form requires 24 hour, 7 day week operation in order to be economically feasible. Also, large volumes of Water must be used to form the necessary screen slurry, with the result that many of the desirable constituents of the natural tobacco are leached out by and lost in the excess Water that drains from the screen. After forming the rudimentary sheet on the screen, the water remaining therein must be evaporated, either by heat or prolonged air drying, which further removes some of the desirable volatile tobacco components, easily lost because of the large surface exposure of the fine tobacco particles. After drying, the reconstituted sheet is relatively brittle and cannot be Vfreely handled without loss in subsequent manufacturing from any source with a tasteless and odorless thermoplastic resin having a relatively low softening point, working the mixture under such conditions that the frict-ion between the tobacco particles and the resin and between each other generates suihcient heat to soften the resin so that the particles and resin flow together and may be formed into a sheet, ribbon or the like, which when cooled to remove the heat of friction, results in a homogeneous body which is self-sustaining but suffi- More particularly, the invention comprises grindingy to relatively uniform particle size waste tobacco such as stems, leaf scraps, particles andV dust resulting from leaf stripping, storage, manufacture and handling, then intimately mixing the ground tobacco with a water-insoluble resin, such as the polymeric vinyl ester type, preferably with a suitable plasticizer for the resin, and adding such sweetening and flavoring materials as may be desired for the finished product. The resin may be in the form of granules or an emulsion or solution thereof andmay be mixed with the plasticizer before admixture with the tobacco, with the flavoring materials added during the tobacco-resin mixing operation. The resulting dry or substantially dry mixture is then worked under pressure by a milling operation between a series of rollers or by pressure extrusion through an extrusion press until the heat generated by the friction between the resin and the tobacco particles, and between each other, reaches or slightly exceeds the softening point of the resin, whereupon the mixture becomes plastic and the particles flow together into a homogeneous mass which, when cooled .to remove the auto-generated heat, results in a solid, self- Referring to the drawings, and-with particular reference to FIGS. 1 and 2, the admixture of at least 60% by weight of dry ground tobacco, at a fneness of 8 mesh per square inch or less, from any source, mixed with not more than 40% by weight of a water-insoluble thermoplastic binder, e.g. a granular polyvinyl acetate resin, is fed by gravity from a hopper 10 to a distributing slot as a layer 11 across a travelling steel beltr12, driven at slow speed, e.g. 10 feet per minute, by chain 13 from motor 14. The belt 12 carries the tobacco-resin mixture,

Vlevelled by xed blade 15 to a thickness of about l/s inch, into the nip of two rollers 16, 17, driven at the same peripheral speed but in opposite directions by aV chain 18 from motor 19 and a sprocket 20 and chain 21 from motor 14.

As the tobacco-resin mixture passes along with belt 12 into and between the nip of rollers 16 and 17, which may be knurled to increase the friction of their surfaces, the mixture is worked by a milling operation in the first stage. This milling operation involves considerable interparticle mixing and consequent friction between the resin and the tobacco particles and between the resin particles and the tobacco particles. This pressure milling or working generates considerable frictional heat but not enough heat to soften the resin to the adhesion point, which in the case of polyvinyl acetate is about 92 C; However, sufficient bonding takes place to effect non-selfsupporting coherence, particularly when the rollers are closely-spaced. To that end, the rollers 16, 17 are xedly but adjustably Vjournalled in frame 26 so as to be spaced fapart about 0.003 to 0.01 inch at the nip. Hence, theresin-tobacco layer is gradually compressed from about 1A; to as little as 0.003 inch as it enters the nip from between the flaring surfaces of the rollers 16, 17. As the result, the autogenous heat friction forms the resin-tobacco mixture into c aisaers the rudimentary sheet or ribbon S, which, being nonselfsustaining, requires support by the platform 27.

As it Aemerges from between the rollers 15, 17, the heat softenedrsheet or ribbon S expands to about double the nip thickness, i.e. about0.006` to 0.02 inch, and also tends 24, 25; Doctor blades 29 engage the surfaces of rollers 22, 23, alsobeing adjustably mounted on the frame 26.

Further milling of the tobacco-resin mixture to secure Y the requisite homogeneity and the self-supporting properties may be desired for the sheet or ribbon S, which is at least partially unitarily bonded as it emerges onto plat- Vform 30 from between rollers 22,. 23. Hence a third set of milling rollers 31, 32, preferably spacedapart the same distance as are rollers 16, 17 and 22, 23, may be pro- Y vided and are driven a-t the same surface speed as those preceding rollers by the respective chains 18 and 21, meshing with corresponding sprockets 33 and 34 xed to the shafts of yrollers 31, 32. Y Y

The autogenously heated andbonded sheet or ribbon VS emerging from between the third set of rollers 31, 32 is stripped therefrom by fixed doctor blades 35 and, ex-

i tween compression rollers 16', 17', onto platform 45 following doctor blades 46 enters the cylinder 47 of the extrusion press to be severed and compressed by reciprocating piston 48 driven by crank wheel 49. The piston 43 forces the severed sheet S" into the converging funnel Si?, where it is compressed with increasing friction-generated heat, which softens the resin still more to the point where it iiows and bonds Vthe tobacco particles together.

The highly compressed and hot tobacco-resin mixture emerges from funnel 50- as a homogeneous self-sustaining rod or ribbon R, which may be severed into short lengths for admixture with chewing tobacco or used directly as panding to a thickness of at least about 0.006 to 0.02

inch, is supported on platform 3.6. Y

Depending on the thermoplastic resin selected and upon the degree of self-sustaining strength and flexibility desired'for the finished sheet, a fourth and even a fifth set of milling rollers may be desired. Considering the fourth set, rollers 37, 38 are preferably spacedapart 0.003 to 0.01 inch-and drivenV at the same peripheral speed of preceding rollers 31,732 by respectively ohainsV 18 and 21 as shown in FIG. l. These rollers 37, 38 recompress the sheet, or ribbon AS entering their nipV from platform f 36 and consequently further mill and thus add more friction-generated heatV thereto, so that greater strength and flexibility are added. Accordingly sheet or ribbonV S emerges from between rollers 37, 38 and doctor blades 39 onto platform 40 in finished form, requiring only removal of the residual friction heatV and that may be simply accomplished by cool air`jets fromrheader 41 .extending 19. The severed lengths S' are collected in container 44 for formationinto cakes, plugs, small sheets or akes,

sliced into narrow strips or the like, depending on requirements. Y Y

Where roller sets additional to the four sets shown in FIG. l are desired or required, it will be understood chewing tobacco, depending on requirements.

As stated, the preferred binder is a resin of the polymerio vinyl ester type such as polyvinyl acetate derived from an acid containing only two carbon atoms. Resins of this type are preferred because they are not only water-insoluble, thus precluding the nished productfrom becoming sticky or friable in moist katmosphere and enabling treatment by added flavoring compounds without damage, but also because such resins are odorless and tasteless, thus leaving available the full liavor of the tobacco without impairment of taste by the resin. However, because such resins burn with an odor considered by some to be unpleasant, therproduct of this invention has greatest utility in or as chewing tobaccos with or with- Vout sweetening or flavoring additives such as licorice,

fruit extracts, molasses and sugar. The product is not appreciably attacked by casing solutions or saliva, but will release the included tobacco and added avoring materials in the same way and at the same rate as does the highest quality chewing tobacco. Although the product is best adapted for chewing purposes, small quantities thereof may be mixed with smoking pipe or cigarette tobacco without noticeably affecting the odor or taste of the latter.

The preferred polymeric vinyl ester resin is polyvinyl acetate, commercially known as Elvacet 81-3300 or Vinac B7 for example, or a mixture of polyvinyl acetate and polyethylenevinyl acetate, commercially known as Elvax 150 or Elvax 250, for example. The physical properties of flexibility and toughness imparted by these resins to the iinished product may be varied by choosing from the various commercial grades thereof with respect to molecular weight chain length or degree of cross-linking andV branching.V Thus, the higher molecular weight yor more crosslinked material gives a tougher, less flexible product, whereas a resin of this type having a low molecular weight gives a more liexible and less tough product. The resin may be used as an emulsion with water, as a solution with an organic solvent such as ethanol or as a solid in the form of small beads or powder, all easily and equally usable. Where a resinvsolvent such as ethanolV is preferred, the solvent evaporates quicklyfrom the sheet or oration is hastened by the heat of compression.

The preferred plasticizer is chosen from that group v which has been government-approved for use as food that they will be driven in the same way as thepreceding roller sets.

The heat of friction for autogenously binding the finely.- divided particles together with a thermoplastic resin such as the polymeric vinyl ester type may also be provided by extruding the tobacco-resin Vmixturenndf'sr pressure, through a progressively contracting tube in a'known manner. However, it is preferred that the extrusion step follows the milling or working step afforded by at leastthe first set of rollers i6, 17 shown in FIG.` l, in order to otbain the desired homogeneity of mixing with some bonding provided by the initial heat of compression between the rollers.k Thus, as shown semi-schematically in FG;

mixer.

additives, eg., triacetin, and may be mixed with the resintobacco mixture before it is fed to the hopper 10. Flavoring compounds may be Vadded before or after hopper 10,

as by dusting or sprayingthe sameon initial layer 1'1.

Typical examples of methods of compounding the ingredients and the resultingproducts according to the invention are as follows:

Example I Two grams of triacetin were mixed well with 36 grams of a water emulsion of polyvinyl acetate containing 55% solids. After thorough mixing, this emulsion was added to 40 grams of powdered cigar leaf tobacco. y The resulting mixture was thoroughly blendedin a Muller type Four grams of powdered sugar and 1 gram of powdered licoricewere added and the blending continued for 20 minutes. VIt should be noted that the blending time is not critical and can be shortened to a small fraction of that mentioned here if it is so desired.

added to the above mentioned compositions in amounts up to 20% of the weight of `the tobacco used, providing After the desired amount of blending the material was Example II Two grams of triacetin were added to 33.4 grams of a 60% solution of polyvinyl acetate in ethanol. This solution was well stirred into a mixture of 40 grams of cigar tobacco, 4 grams of powdered sugar and 1 gram of powdered licorice. Most of the ethanol was-removed from this mixture by means of a belt drier.V The resulting powder was then fed into a set of rollers with the spacing set as indicated in the previous example. The material from the lirst set of rollers was fed into a second set and so forth until a continuous ribbon was formed. In this instance, live sets of rollers were required.

It was not necessary to remove all of the ethanol in the drying operation since the remainder was driven off by the heat generated by the milling action of the rollers.

' This milling action also achieved the tinal blending of the plasticized resin with the other materials in the product.

As was the case in the previous example, the ribbon formed was approximately twice the thickness of Vthe space between the rolls used in the final rolling.

Example III Two grams of triacetin were stirred into 20 grams of powdered polyvinyl acetate. The resulting moist powder was mixed with 40 grams of kground tobacco, 4 grams of powdered sugar and 1 gram of powdered licorice. Thev resulting free ilowing powder was fed into the first of four sets of rollers with the roll spacings set as previously described. The product emerged from the fourth set of rollers as a continuous ribbon whose thickness was approximately twice the spacing of the final set of rolls. Good mixing of the ingredients prior to rolling was not found to be essential since this was accomplished by the milling action of the first two sets of rollers.

Example l V rollers in succession with the spacing of each set adjustedl so as to have a clearance of approximately 0.003 inch. The product emerged from the last set as a continuous ribbon with an average thickness of about 0.006 inch.

Liquid avoring materials such as corn syrup, molasses, fruit extract and dry or solid avoring materials such as powdered sugar and powdered licorice, etc., may be only that they Yare not Volatile and are not decomposed by heat below C.

Operation of the apparatus and conduct of the processof this invention will be evident from the foregoing de- Y scription thereof, whereby there is and may be produced a new chewing tobacco product which, when chewed, releases the tobacco taste and davor from the individual tobacco particles, which, because of their relatively small size, expose and present a large aggregate surface area for soluble cooperation'with the saliva of the chewer. At' the same time, the resin binder, being chewable, holds the tobacco particles together in and as a plastic mass, whose plasticity increases with the warmth of the chewers mouth but does not become fluid so as to lose its plastic coherence.

The sheets, ribbons or rods may be further subdivided and mixed with chewing leaf or used alone and after being formed into cakes or fplugs, small sheets, akes, or other desired forms or shapes may be marketed in the usual way.

Y Although certain preferred proportions of tobacco fines to binder and iavoring components have been speciied` in the foregoing examples, it is to be understood that the invention is not limited thereby or thereto, but is susceptible of changes in form andjdetail within the scopeof the appended claims.

We claim:

1. A chewing tobacco product comprising in excess of 60% by weight of finely-divided tobacco thermally bonded together by and dispersed in a matrix of less than 40% and more than 20% by weight of a water insoluble polymeric vinyl ester resin plasticized with triacetin, said product being of Chewable plasticity at body temperature to release tobacco iiavors without disintegration.

2. A chewing tobacco product comprising in excess of 60% by weight of finely-divided tobacco thermally bonded together by and dispersed in a matrix of less than 40% and more than 20% by weight of a tasteless water insoluble mixture of polyvinyl acetate and polyethylene vinyl acetate having a softening point of less than C., and plasticized with triacetin, said product being of Chewable plasticity at body temperature to release tobacco avors without disintegration. Y

References Cited in the file of this patent UNITED STATES PATENTS 

1. A CHEWING TOBACCO PRODUCT COMPRISING IN EXCESS OF 60% BY WEIGHT OF FINE-DIVIDED TOBACCO THERMALLY BONDED TOGETHER BY AND DISPERSED IN A MATRIX OF LESS THAN 40% AND MORE THAN 20% BY WEIGHT OF A WATER INSOLUBLE PLYMERIC VINYL ESTER RESIN PLASTICIZED WITH TRIACETIN, SAID PRODUCT BEING OF CHEWABLE PLASTICITY AT BODY TEMPERATURE TO RELEASE TOBACCO FLAVORS WITHOUT DISINTEGRATION. 